Oriented high density polyethylene film, compositions and process suitable for preparation thereof

ABSTRACT

The draw ratio and/or rate of stretch of HDPE in film orientation can be increased, or the breakage frequency at a given draw ratio and draw rate decreased by the addition of an orientation improving amount of a normally solid fatty carboxylic acid having a melting point lower than the orientation temperature of the film.

This is a divisional of copending application(s) Ser. No. 09/925,818filed on Aug. 9, 2001.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention pertains to oriented film of high densitypolyethylene, to compositions suitable for the preparation thereof, andto a process for its preparation.

2. Background Art

Polyethylene is available in numerous forms required of the various anddistinct end uses for which it is destined. Polyethylene may be roughlydivided into low density and high density grades. Within each grade,polyethylene may exhibit a variety of melt temperatures, melt flowratios, melt viscosities, and the like. The physical properties of eachtype of polyethylene must be closely tailored to the specific end use;otherwise processing becomes problematic or even impossible. Thus, it isimpossible, in general, to employ a polyethylene composition tailoredfor one type of processing in another type of processing. For example,low density polyethylene (LDPE) is widely used for preparation of films,and finds uses in such items as cargo wrap and plastic refuse bags. LDPEis relatively easy to formulate for such uses, and may contain numerousingredients in addition to LDPE itself, i.e., pigments, UV absorbers,thermal stabilizers, plasticizers, lubricants, etc.

Oriented high density polyethylene (HDPE) is an altogether differentproduct, and is formulated differently than its LDPE relative. Byorienting HDPE, the strength and stiffness properties are markedlyimproved. As a result, stronger, and optionally thinner films may beprepared. The higher density and, in general, different physicalproperties of HDPE require different processing considerations, andorientation adds additional complexity. Oriented HDPE is generallyextruded as a film, and water quenched. Films may also be chill rollcast, or blown and air quenched. The film is then uniaxially orbiaxially stretched, optionally followed by annealing. The stretchingoperation takes place below the melt temperature, and may be termed a“hot stretch.” The stretching operation must take place without anysubstantial likelihood of breakage, as breakage requires that the entireorientation process be restarted, increasing process down-time andgreatly increasing cost.

A variety of different types of HDPE may be successfully oriented asfilm, and such HDPE is commercially available. However, oriented filmproduced from such compositions is not necessarily optimal for certainapplications, and thus improvements in HDPE oriented film are desirable.Moreover, up till now, solution processed HDPE has proven to beextremely difficult to prepare as oriented film. Solution-polymerizedHDPE is prepared by polymerizing ethylene in solution, following whichthe solvent is removed and the polymer is pelletized.Solution-polymerized HDPE tends to stretch inconsistently, and thus therate and/or amount of stretch must be decreased in order to orient thefilm without breaking, if orientation can be performed at all.Decreasing the amount of stretch generates a product having differentand generally less desirable physical properties, while decreasing therate of stretch results in increased production time and cost.

SUMMARY OF THE INVENTION

The present invention pertains to an HDPE composition containing anormally solid, long chain carboxylic acid having a melting point belowthe orientation temperature of the HDPE film. The compositions, evenwhen employing solution-polymerized HDPE, have been found to stretch atcommercially useful rates and stretch ratios without undue breakage. ForHDPE which can be stretched without additives, adding long chaincarboxylic acids lowers further the already low frequency of breakageoccurring during commercial manufacturing processes, and may result inhigher physical properties as a result of greater uniformity in thestretching operation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

The HDPE used in the present invention is that conventionally recognizedas HDPE by the skilled artisan, i.e., polyethylene homopolymers orcopolymers having a density of from 0.94 to 0.965. In general,copolymeric HDPE contains 20 weight percent or less, particularly 10% byweight or less of copolymerizable comonomers. Suitable comonomers arewell known in the art, with preferred comonomers being butene, hexene,and octene. The polyethylene may be made by conventional catalysts,i.e., of the Ziegler-Natta type, or may be made employing a wide varietyof single site catalysts, for example STAR™ ethylene polymerizationcatalysts developed by EQUISTAR, Cincinnati, Ohio. Processes forpreparing HDPE include all those in common use, including gas phase,slurry, and solution processes. Solution processed polyethylene is thepreferred polyethylene in the present application. The resultantpolyethylene, optionally including thermal and/or UV stabilizers, iscommonly extruded and pelletized to form a polyethylene “raw material”.

The HDPE polyethylene raw material is extruded through a die into film.Prior to or while in the extruder, the HDPE raw material is compoundedwith any additional ingredients, generally including dyes and/orpigments, thermal and/or UV stabilizers, etc. These may be dosed intothe extruder by themselves, or in master batches of HDPE containinglarger than desired amounts of additives. Alternatively, master batchescontaining the desired ingredients may be mixed in the appropriateproportions with the HDPE raw material prior to entry into the extruder.The HDPE preferably contains no fillers, especially fillers which wouldcause disruption of the film such as the formation of voids.

In the present invention, the ability to stably orient extrudedpolyethylene films is induced or augmented by the addition of a smallquantity of a normally solid carboxylic acid, one having a melting pointbelow the film orientation temperature, preferably stearic acid,palmitic acid, or mixtures thereof, and most preferably, palmitic acidalone. Other low melting but normally solid fatty carboxylic acids maybe used as well, one example being lignoceric acid. While the fattycarboxylic acids may contain ethylenic unsaturation, they must benormally solid, i.e. solid at 25° C. Thus, numerous common unsaturatedfatty acids such as oleic acid, linoleic acid, and linolenic acid arenot suitable for use herein, although they may find themselves useful aslubricants or plasticizers in very small amounts. The preferred fattyacids are saturated fatty acids, most preferably linear fatty acids suchas occur in natural products, preferably natural products of vegetableorigin.

The manner in which the normally solid, low melting fatty acid functionsis not known with certainty. Without wishing to be bound to anyparticular theory, it is presently believed that the long chain fattyacids, having a structure similar to polyethylene, is able to behomogeneously dispersed in the polyethylene, where it functions to allowgreater mobility between adjacent polyethylene polymer chains. Thegreater mobility is thought to reduce the inconsistencies otherwiseassociated with the orientation of polyethylene polymers.

The amount of solid, fatty acid is an amount effective to alloworientation without undue breakage, while maintaining desirable endproperties. The actual amount is dependent to some degree on theparticular HDPE, and thus may vary. However, the amount is virtuallyalways less than 1% by weight (10,000 ppm), more preferably from about200 ppm to 5,000 ppm, yet more preferably between 500 ppm and 3,000 ppm,and most preferably about 2,000 ppm, these weights in parts per millionbased on the sum of the weights of the polyethylene and the carboxylicacid in the finished composition. It should be noted that in addition tofacilitating orientation, many of the properties of the oriented filmare improved as well.

The solid, fatty acid is preferably supplied as a master batch,dispersed in the same or another HDPE. In certain circumstances, LDPE,LLDPE or other polyethylene homopolymers or copolymers may be introducedas well. Preferred master batches contain stearic acid or palmitic acidat a level of from 1 weight percent to 5 weight percent, preferably 1weight percent to 3 weight percent, and most preferably 1.5 to 2.5weight percent. The polyethylene used in the master batch may be thesame or different from the polyethylene to which the master batch willbe added, but is preferably the same or substantially similar. Suitablebase resins include, in a non-limiting sense, the Alathon® polyethyleneresins manufactured by Equistar Corporation, including L5845 with a meltindex of 0.45 and density of 0.958 g/cm³; L5045, with a melt index of0.45 and a density of 0.950 g/cm³; LT618072, with a melt index of 1.0and a density of 0.960 g/cm³; PE4829, with a melt index of 0.34 and adensity of 0.944 g/cm³; and L5885 with a melt index of 0.85 and adensity of 0.958 g/cm³. These are illustrative and not limiting.

The master batches are generally prepared conventionally in a singlescrew or twin screw extruder, although other devices such as Henschelmixers, Banbury mixers, Brabender mixers and other mixers may also beused. The carboxylic acid is generally mixed in at relatively low shear,and thus for a resin with a melt temperature below 285° F. (140° C.),temperatures of 360° F. (182° C.) to 400° F. (204° C.) are suitable,although higher or lower temperatures may be used as well. The masterbatches preferably contain no stearates such as zinc stearate. Followingmixing, the master batch is generally granulated.

The master batch is added to the desired HDPE in an amount sufficient toprovide the necessary resistance to breaking during film orientation,for example 2,000 ppm relative to the final HDPE product. The HDPE isextruded into film and generally quenched by conventional processingmethods, i.e. by chill rolls, air quenching, water quenching, etc.Following film preparation, the film may optionally be slit, i.e., forforming tape, and is uniaxially or biaxially oriented. The orientationtakes place at a temperature which is preferably above the line drawingtemperature, and below the melt temperature. If necking can betolerated, lower temperatures may be used.

The term “line drawing temperature” refers to the temperature abovewhich uniform orientation is obtained, as is known in the art. The linedrawing temperature and melting temperature can be determinedexperimentally. When the film is stretched at temperatures low enoughfor line drawing, a “line” or “neck” develops in the film, perpendicularto the direction of stretch once the yield point has been reached.Stretching then starts from this thinned-out region until an elongationequal to the natural stretch ratio of the film is achieved, for theparticular stretch rate used. If a series of film samples is stretchedunder conditions of line-drawing at a set of increasingly highertemperatures, starting at room temperature, a series of decreasinglysharp maxima will result in the corresponding stress-strain curves. Atsome higher temperature, a maximum no longer appears in thestress-strain curve, and line drawing has ceased. At this temperature orhigher temperatures, the film undergoes more uniform stretching over itslength and no longer displays a line or neck during elongation. A moredetailed discussion may be found in “Polyethylene” by Renfrew andMorgan, 2d edition, pages 170-2, published in 1960 by IntersciencePublishers, Inc. New York.

The line-drawing temperature can change. For example, a film has a givenline drawing temperature before stretching. However, after stretching inone direction, e.g., the machine direction, the line-drawing temperatureof the film in the direction perpendicular to the direction of stretch,e.g., the transverse direction, is higher than the given temperature.This difference in temperatures should be taken into consideration inorder to provide biaxial stretching at the proper stretching temperaturewhen stretching in the machine direction and transverse stretching arenot performed simultaneously.

The stretching may occur in conventional devices, i.e., between a seriesof pairs of counter-rotating rollers, the temperature of which may varyfrom roll-to-roll. The initial pair of counter-rotating rollers revolveat a lower rate than the last pair, or “exit rollers,” with pairs ofrollers inbetween revolving at intermediate rates. Thus, the exit speedof the film is higher than the input speed and the film is stretchedaccordingly. The term “stretch ratio” is the ratio of a length of asample of the film in the orientation direction, after stretching,compared to the original length of the film in the orientationdirection, before stretching. The “stretch rate” is the rate of changein length of the stretched film over time. The stretch ratio may beadjusted to the desired level, i.e., one which achieves the desiredtensile strength, generally a stretch ratio between 3 and 6, morepreferably between 3.5 and 5, and most preferably in the range of 4.0 to4.5, by increasing the relative differences in revolving rates of theinput and exit rollers.

The optimum temperature for stretching will depend on the particularpolyethylene or blend of polyethylenes selected. As indicated, whenstretching the films, it is necessary for the film temperature to bebelow the melt temperature point and above the line drawing temperature.In practice, the actual sheet or film temperature is not usuallymeasured. Instead, what is measured is, for example, the temperature ofthe fluid used to heat orienting rolls in a machine direction orienter,or the air temperature in a tenter frame oven.

For example, the rollers may be contained within a stretch oven, whichis preferably maintained at a temperature above the melt temperature ofthe polyethylene. Because of the speed of travel of the web through theoven, however, the film temperature never rises above the melttemperature, and thus the stretching takes place in the solid state. Theorientation temperature may be up to just less than the melttemperature, generally about 130° C., but is preferably below 125° C.,more preferably in the range of 80° C. to 120° C., and most preferably100° C. to 115° C.

If biaxial orientation is desired, the film is not slit prior tostretching (but may be slit afterwards), and enters the oven in a tenterframe, as shown in FIGS. 2 and 3. A series of clamp-like devices clamponto the edges of the film and move apart relative to each other both inthe transverse and lateral directions. The film is thus stretched bothacross its width (transverse) and along its length (laterally). Thestretch ratio may be the same or different in these directions. Acombination of roller stretching (monoaxial) and transverse stretchingin a tenter frame may also be employed, or any combination. Followingstretching, whether monoaxial or biaxial, the resulting film or tape isoptionally annealed in the annealing oven. Following exit from theoptional annealing oven, the product may be wound onto rolls or bobbins(i.e., for tape), may be woven, and/or laminated to other films. Thetape may be woven into woven products. The oriented product has hightensile strength due to the stretching operation below the melttemperature, and is a coherent product, for example exhibiting a lack ofmicrovoids.

Having generally described this invention, a further understanding canbe obtained by reference to certain specific examples which are providedherein for purposes of illustration only and are not intended to belimiting unless otherwise specified.

EXAMPLE 1 AND COMPARATIVE EXAMPLES C1-C4

A master batch of 2 weight percent palmitic acid in a solution-typepolyethylene homopolymer (Alathon® L5885 polyethylene) with a melt indexof 0.85 and a density of 0.958 is preferred, by mixing the ingredientsunder low shear at 360° F. to 400® F. until a homogenous product isobtained. The master batch is then extruded and pelletized. Films ofAlathon® L5885 polyethylene base resin with and without palmitic acidderived from the master batch are air blown and quenched. The propertiesof the films as prepared (non-oriented), and at stretch ratios of 4:1and 5:1 are measured. The results are presented in Table 1.

TABLE 1 Example C1 C2 C3 C4 1 Palmitic Acid 0 0 0 2000 2000 Film TypeNot Oriented Oriented 4:1 Oriented 5:1 Not Oriented Oriented 5:1 Gauge(mil) 4.13 1.1 0.92 4.02 1.0 Dart Drop (F50) 183 <36 <36 186 <36Elmendorf Tear 80/440 6/Breaks MD 5/410 78/440 5/350 (MD/TD)¹ Gloss(units) 5.9 17 23 5.8 30 Haze (%) 81 54 44 81 34 1% Secant Modulus151340/203960 258590/258590 346170/281540 148500/198030 360660/274570(psi) (MD/TD) Puncture (Newtons) 91.1 13.2 9.7 94.3 13 TEDD 1.5 0.440.44 1.5 0.52 Yield (psi) (MD/TD) 4290/4850 15600/4400 28400/39204210/4630 30300/3040 Elongation at Yield 10/5 20/3 19/2 11/5 19/2 (%)(MD/TD) Break (psi) 5970/4220 17100/2520 20800/3320 6330/5510 23600/3290(MD/TD) Elongation at Break 740/640 110/15 36/6 790/980 31/4 (%) MD/TDWVTR (g/m²/day) 0.76 1.84 2.19 0.64 2.22 ¹MD = machine direction; TD =transverse direction

The results presented in Table 1 illustrate the improvement inorientation obtainable through use of the low melting, normally solidfatty acids of the present invention. Particularly noteworthy is thedecrease in haze, the increase in elongation at yield, and the tensilestrength at break. The amount of haze is related to the ability of thefilm to stretch uniformly. The greater the uniformity, the less haze.Solution processed polyethylene, for example, stretches inconsistently,producing considerable haze. Products with less haze are also viewedmore favorably by the purchaser. The addition of only 2000 ppm palmiticacid lowered the relative amount of haze by approximately 25 percent.

At the same time, the tensile strength at break in the machine directionis increased by ca. 10%, even though the film is slightly thinner (1.0mil versus 1.1 mil). This increase in breaking strength, and theimprovement in haze, are accomplished without significantly affectingother properties such as elongation at yield or Elmendorf tear strength.The puncture strength shows significant improvement as well.

A further indication of the ability of the low melting, normally solidfatty acids of the subject invention to improve processing is the “TMLong” Test, a non-standard test where necking-in is prevented bymaintaining the edges of the film at a fixed distance duringlongitudinal stretch. This test is particularly sensitive, and allowsobservation of effects which less sensitive tests do not.

EXAMPLES 2. C5 AND C6

Films of Alathon® L4903 polyethylene resin with a density of 0.949 and amelt index of 0.027 was oriented using the “TM Long” test describedabove. In the comparative example, no processing aid was added. In thesubject invention example, 2000 ppm palmitic acid was included in theformulation. The results are presented in Table 2 below. The orientationwas performed at 110° C.

TABLE 2 Palmitic Draw Draw Example Acid Ratio Rate Comments C5 None4.0:1 70 mm/s Broke C6 None 4.0:1 40 mm/s OK 2 2000 ppm 4.0:1 70 mm/s OK

The results in Table 2 indicate that the HDPE with no processing aidcould be stretched at a draw ratio of 4.0:1 and a draw rate of 40 mm/s.However, at a higher draw rate of 70 mm/s, the film broke. By adding2000 ppm palmitic acid, the film could be satisfactorily stretched at adraw rate of 70 mm/s.

While embodiments of the invention have been illustrated and described,it is not intended that these embodiments illustrate and describe allpossible forms of the invention. Rather, the words used in thespecification are words of description rather than limitation, and it isunderstood that various changes may be made without departing from thespirit and scope of the invention.

What is claimed is:
 1. A substantially microvoid-free oriented HDPE filmhaving a draw ratio in excess of 3, said film free of metal stearates,and comprising a) HDPE having a density from 0.94 to 0.965 g/cm³, and b)from 0.02 to 1 weight percent of a normally solid fatty carboxylic acidhaving a melting point below the temperature at which said film wasoriented, said weight percent relative to the sum of a) and b).
 2. Thefilm of claim 1, wherein said fatty carboxylic acid is selected fromfatty carboxylic acids having melting points between 60° C. and 100° C.3. The film of claim 1, wherein said fatty carboxylic acids are selectedfrom stearic acid, palmitic acid, lignoceric acid, and mixtures thereof.4. The film of claim 1, wherein said fatty carboxylic acid is palmiticacid.
 5. The film of claim 1, wherein said orientation temperature isbelow 120° C.
 6. A master batch for addition to HDPE to increase theamount or rate of stretch without breakage or to decrease the frequencyof breakage at a given amount and rate of stretch, said master batchbeing free of metal stearates, and comprising HDPE or a mixture of HDPEand another polyethylene homo- or co-polymer of lower density, and from1.5 to about 5 weight percent of a normally solid fatty carboxylic acidhaving a melting point less than 100° C.
 7. A master batch for additionto HDPE to increase the amount or rate of stretch without breakage or todecrease the frequency of breakage at a given amount and rate ofstretch, said master batch being free of metal stearates, and comprisingHDPE or a mixture of HDPE and another polyethylene homo- or co-polymerof lower density, and one solid fatty acid component consisting of from1.5 to about 5 weight percent of one or more normally solid fattycarboxylic acids having a melting point less than 100° C.
 8. The masterbatch of claim 7, wherein the only fatty carboxylic acids present areselected from the group consisting of stearic acid, palinitic acid, andmixtures thereof.